Issue link: https://www.ascpskindeepdigital.com/i/1503366
Exclusive member benefit: Get the ASCP SkinPro app at ascpskincare.com/skinpro 73 guide brands in the right direction when it comes to packaging in the R&D stages. STEP 2: SAMPLE CREATION After the initial R&D phase, a sample is created according to the company's requirements. Samples are created using smaller lab equipment and are usually around 30–60 grams (g) in size. After testing the sample and reviewing the ingredient list, the company decides whether to approve and go forward with production or make a revision and submit changes. Usually, the lab will allow up to three revisions to be made to the sample. Once the company has approved the sample, it is then tested in the chosen packaging to ensure stability. After that, the raw materials are ordered from a variety of suppliers based on what the company wants. At last, production is scheduled. STEP 3: THE PILOT BATCH Pilot batches are the first time a formula is made on a larger scale to understand the challenges in bringing it from a small lab sample to full-scale production. Full-scale cosmetic production can range from 100 to 300 kilograms and takes place in large homogenizers. Cortopassi says it is very risky to jump from a small lab sample to full-scale production (300 kg) without running the pilot batch (15–20 kg) to ensure the quality is precise. This is because the lab samples are made with smaller lab equipment, whereas the mass production gets made with large homogenizers. STEP 4: PREPARING FOR PRODUCTION After the lab runs the pilot batch, the lab team can prepare for full-scale production. Everything in production must be sanitized, the equipment calibrated, and all ingredients weighed. Individuals are required to follow specific protocols when entering the clean zones, including changing into special clothing before entering the production areas where the product is made. Manufacturing areas, also called clean rooms, require safety glasses, hairnets, beard nets if facial hair is present, long-sleeve lab coats, shoe covers, and gloves. For pharmaceutical products, the lab coat is swapped for a full-length disposable dress. Sinks are present for handwashing. A constant temperature of 72 degrees is maintained for the comfort of the team.